Device for the additive production of a three-dimensional object

ABSTRACT

An apparatus ( 1 ) for additive manufacturing of a three-dimensional object by successive layer-by-layer selective illumination and thus selective solidification of construction material layers ( 9 ) formed in a construction plane ( 10 ), consisting of a solidifiable construction material ( 2 ) by means of at least one energy beam ( 3 ), comprising a housing structure ( 4 ), and a combined coating and illumination assembly ( 6 ) firmly arranged or formed on the housing structure ( 4 ) of the apparatus, comprising a coating device ( 8 ) provided for applying the construction material ( 2 ) into the construction plane ( 10 ) and for forming construction material layers ( 9 ) to be solidified in the construction plane ( 10 ), and an illumination device ( 11 ) provided for the selective illumination of respective construction material layers ( 9 ) formed in the construction plane ( 10 ) by means of the coating device ( 8 ), and a carrying device ( 15 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a United States national stage entry of anInternational Application serial no. PCT/EP2017/054498 filed Feb. 27,2017 which claims priority to German Patent Application serial no. 102016 105 097.0 filed Mar. 18, 2016. The contents of these applicationsare incorporated herein by reference in their entirety as if set forthverbatim.

The invention relates to an apparatus for additive manufacturing of athree-dimensional object by successive layerwise selective illuminationand consequent selective solidification of construction material layersof solidifiable construction material, which are formed in aconstruction plane, by means of at least one energy beam.

Such apparatuses for additive or generative manufacturing ofthree-dimensional objects are known per se. By means of correspondingapparatuses, three-dimensional objects to be manufactured areconstructed additively, or generatively, by successive layerwiseselective illumination and consequent solidification of successiveconstruction material layers of solidifiable construction material,which are applied in a construction plane, in respective regionscorresponding to cross-sectional regions of the objects respectively tobe produced, by means of an energy beam.

Because of their design configuration, known apparatuses requireseparate carrying out of coating and illumination processes; coating andillumination processes are therefore carried out chronologicallyseparately from one another. These include, for example, apparatuseshaving an optionally movably mounted illumination device and a carrierdevice, which is arranged positionally fixed with respect thereto in thehorizontal direction and comprises a carrying element comprising theconstruction plane. These apparatuses require further development with aview to reducing nonproductive times, or optimizing the constructiontime.

The object of the invention is to provide an apparatus which is improvedin relation thereto, particularly with a view to reducing nonproductivetimes, or optimizing the construction time, for the additivemanufacturing of a three-dimensional object.

The object is achieved by an apparatus as described herein. The claimsrelate to particular embodiments of the apparatus. The object isfurthermore achieved by a method as described herein.

The apparatus described herein is used for additive or generativemanufacturing of at least one three-dimensional object, i.e. for examplea technical component or a technical component group, by successivelayerwise selective illumination and consequent selective solidificationof individual construction material layers of solidifiable constructionmaterial by means of at least one energy beam.

The solidifiable construction material may be a metal powder, plasticpowder and/or ceramic powder. A metal powder, plastic powder or ceramicpowder may also be understood as a powder mixture of different metals,plastics or ceramics, respectively. In the case of a metal powder, itmay in this regard also be a powder of at least one metal alloy. Theenergy beam may be a laser beam. The apparatus may correspondingly be anapparatus for carrying out selective laser melting methods (abbreviatedto SLM methods) or selective laser sintering methods (abbreviated to SLSmethods).

The successive selective layerwise illumination and the consequentsuccessive layerwise selective solidification of the constructionmaterial layers to be solidified in order to manufacture athree-dimensional object (referred to below as the “object” for brevity)is carried out on the basis of object-related construction data. Theconstruction data describe the geometrical or geometry-designconfiguration of the object to be manufactured. The construction datamay, for example, be or contain CAD data of the object to bemanufactured.

The apparatus comprises all the functional component parts typicallyrequired in order to carry out additive construction processes. Thefunctional component parts can be or are typically arranged in a housingstructure of the apparatus, which may optionally also be referred to orconsidered as a machine housing.

The apparatus comprises at least one combined coating and illuminationassembly (referred to below as an “assembly” for brevity). The assemblycomprises a coating device. The coating device is configured in order tocarry out material application processes for applying constructionmaterial onto the construction plane and in order to carry out coatingprocesses for forming construction material layers to be selectivelyilluminated, or to be selectively solidified, in a construction plane.In a respective application process, a particular amount of constructionmaterial is applied onto the construction plane. In a respective coatingprocess, a construction material layer to be selectively illuminated, orto be selectively solidified, with a defined layer thickness istypically formed from construction material applied onto theconstruction plane in the scope of an application process. The coatingdevice comprises at least one application element, typically arrangedabove the construction plane and in particular comprising at least oneapplication opening, which can typically be closed by a closure elementthat can be moved between an open and a closed position, for applyingconstruction material onto the construction plane, and at least one, inparticular a blade-like or blade-shaped, coating element (“coatingblade”), typically arranged above the construction plane, for forming aconstruction material layer to be selectively illuminated, or to beselectively solidified, with a defined layer thickness.

Besides the coating device, the assembly comprises an illuminationdevice. The illumination device is configured in order to carry outillumination processes for selective illumination and consequentselective solidification of construction material layers formed in theconstruction plane by means of the coating device. In a respectiveillumination process, a construction material layer formed by means ofthe coating device is typically illuminated selectively, and thereforesolidified selectively. The illumination device may comprise one or moreillumination element(s), typically arranged above the constructionplane. An illumination element may be a laser diode element or anoptical element, particularly in lens form, which can be or is coupledto a laser diode element, or a scanner element as part of an opticalscanner device, also to be referred to or considered as a beam steeringdevice, or a corresponding illumination element may comprise at leastone of the elements mentioned. Because of the, optionally variable, beamproperties of the laser beams which can be generated by them,illumination elements in the form of laser diode elements may beparticularly expedient. As will be revealed below, laser diode elements,optionally combined in groups, may be arranged in a row and/or columnfashion (“matrix fashion”).

The assembly is arranged or configured statically, or fixed in position,i.e. not movably, on the housing structure of the apparatus. Theassembly arranged or configured statically on the housing structure ofthe apparatus, or the coating device and illumination device associatedtherewith, therefore lies in a defined position, i.e. in particular at adefined distance, and a defined orientation relative to the constructionplane. Static arrangement or configuration of the assembly does notexclude the possibility that the assembly may when required be separatedfrom the housing structure, for example for service and/or repairpurposes. The assembly can therefore be fastened releasably to thehousing structure, the assembly being mounted statically, i.e. notmovably, relative to the construction plane in the state fastened to thehousing structure.

The apparatus furthermore comprises at least one carrying device. Thecarrying device comprises at least one carrying element which comprisesthe construction plane, i.e. the plane in which corresponding coatingand illumination processes are carried out. The carrying element, whichtypically has a plate-like or plate-shaped geometrical configuration, ismounted movably in a horizontally oriented movement plane, or movementpath, relative to the assembly. The respective movements of the carryingelement in the horizontally oriented movement plane, or movement path,are typically linear movements along a linear movement axis (translationaxis).

In order to carry out respective movements of the carrying element inthe horizontally oriented movement plane relative to the assembly,various methods are in principle possible.

In a first variant, the carrying element may be arranged or configuredon or in a movably mounted modular housing structure of the carryingdevice. In the first variant, the modular housing structure is mountedmovably in the horizontally oriented movement plane relative to theassembly. In this case, it is thus not the carrying element itself, butthe entire modular housing structure, on or in which the carryingelement is arranged or configured, that is mounted movably in thehorizontal direction relative to the module. Movements of the carryingelement relative to the assembly therefore result from movements of themodular housing structure relative to the assembly. The carrying elementis arranged or configured statically, at least in the horizontaldirection, on or in the modular housing structure.

In a further variant, the carrying element may be arranged or configuredin a modular housing structure, arranged or configured staticallyrelative to the assembly, of the carrying device. In the furthervariant, the carrying element is mounted on or in the housing structuremovably in the horizontally oriented movement plane relative to theassembly. In this case, it is thus the carrying element itself that ismounted movably in the horizontal direction relative to the assembly.Movements of the carrying element relative to the assembly thereforeresult from actual movements of the carrying element relative to themodular housing structure. The modular housing structure is arranged orconfigured statically, at least in the horizontal direction, on or inthe housing structure of the apparatus.

In principle, a combination of the two variants mentioned above is alsopossible.

In principle, it is the case that the modular housing structure of thecarrying device can be removed in the manner of a replaceable containerfrom the housing structure of the apparatus. The carrying structure cantherefore be removed when required from the housing structure of theapparatus, and fastened when required on the housing structure of theapparatus.

For driving, i.e. for setting the carrying element or the modularhousing structure of the carrying device in a movement in thehorizontally oriented movement plane relative to the assembly, theapparatus typically comprises at least one drive device.

In respect of the first variant, it is the case that the apparatuscomprises at least one drive device, which can be or is coupled to themodular housing structure of the carrying device and is configured inorder to generate a drive force which moves the modular housingstructure of the carrying device in the horizontally oriented movementplane relative to the assembly.

Besides at least one (electric) motor drive unit, by means of which theactual drive force can be generated, the drive device may comprise atleast one transmission unit coupled thereto, by means of which thegenerated drive force can be transmitted to the element to be driven,i.e. the modular housing structure or the carrying element. The drivedevice may be configured as a linear drive, or comprise at least onesuch drive. Specifically, the drive device may be configured for exampleas a crank drive or spindle drive, or comprise such a drive. In order tobe able to produce a guided movement of the modular housing structure inthe horizontal movement plane, or movement path, guide devices, forexample rail-like guide devices, may be arranged or configured on or inthe housing structure of the apparatus.

In respect of the second variant, it is correspondingly the case thatthe apparatus comprises at least one drive device, which can be or iscoupled to the carrying device and is configured in order to generate adrive force which moves the carrying element in the horizontallyoriented movement plane relative to the assembly. Besides at least one(electric) motor drive unit, by means of which the actual drive forcecan be generated, the drive device may in this case also comprise atleast one transmission unit coupled thereto, by means of which thegenerated drive force can be transmitted to the element to be driven,i.e. the modular housing structure or the carrying element. The drivedevice may in this case also be configured as a linear drive, orcomprise such a drive. Specifically, a drive device may be configuredfor example as a crank drive or spindle drive, or comprise such a drive.In order to be able to carry out a guided movement of the carryingstructure in the horizontal movement plane, or movement path, guidedevices, for example rail-like guide devices, may be arranged orconfigured on or in the modular housing structure. The guide devices maybe mounted movably in the vertical direction, in order to carry outlowering of the carrying element.

Besides the described mobility in a horizontal movement plane, ormovement path, the carrying element may thus furthermore be mountedmovably relative to the assembly in at least one further movement plane,or movement path. Such a further movement plane, or movement path, istypically oriented vertically. Respective movements of the carryingelement in the vertically oriented movement plane, or movement path, aretypically linear movements along a linear movement axis (translationaxis) which are characteristic of corresponding additive manufacturingmethods after a coating and illumination process has been carried out.In respect of the drive devices required for the movement of thecarrying element in the vertically oriented movement plane, the commentsrelating to the movement of the carrying element relative to theassembly in the horizontally oriented movement plane apply analogously.

The design configuration of the apparatus described herein allowsmovement of a carrying element, which comprises the construction plane,relative to a combined coating and illumination device. The movement ofthe carrying element relative to the assembly takes place in ahorizontal movement plane, or movement path; the carrying element cantherefore be moved to and fro in a similar way to the principle of aplotter. What is essential in this case is that, as will be explained inmore detail below, both coating and illumination process can be carriedout during respective movements of the carrying element relative to theassembly. Movement of the carrying element relative to the assemblytherefore allows formation, at least in sections, in particular fully,of a defined construction material layer and selective illumination, atleast in sections, in particular fully, of the construction materiallayer formed. The coating and the illumination are in this caserespectively carried out during the horizontal movement of the carryingelement relative to the assembly. The apparatus therefore allowssimultaneous conduct of coating and illumination processes, so that downtimes or nonproductive times can be reduced, possibly even eliminated,and construction times can correspondingly be optimized.

By the static arrangement or configuration of the assembly, i.e. of thecoating and illumination device, adjustment processes of these devicesare furthermore simplified since the assembly typically can be or isarranged in “only” one defined position and orientation relative to theconstruction plane. The position and orientation of the assemblyrelative to the construction plane are optimized in relation to thecoating device, so that the construction material layer that can beformed by means of respective coating elements has desired layerproperties, in particular a desired layer thickness. The position andorientation of the assembly relative to the construction plane arefurthermore optimized in relation to the illumination device, so thatthe energy beam that can be generated by means of respectiveillumination elements strikes a construction material layer respectivelyto be selectively illuminated, or solidified, with desired beamproperties, i.e. for example a desired intensity. The assembly typicallyonly needs to be adjusted once in order to be positioned, or oriented,exactly relative to the construction plane.

Overall, an apparatus for the additive manufacturing ofthree-dimensional objects is provided, which is improved in particularin relation to reduction or optimization of the construction time.

The static arrangement or configuration of the assembly on the housingstructure of the apparatus may be carried out using a receptionstructure, which is fastened on the housing structure and in which atleast the assembly, i.e. the coating device and the illumination device,is arranged or configured in a structurally integrated way. Arrangementor configuration of the coating device and of the illumination device inthe reception structure leads to a structurally compact configuration ofthe assembly. Fastening of the reception structure on the housingstructure of the apparatus leads to exact positioning and orientation ofthe coating device and of the illumination device relative to theconstruction plane. To this end, the reception structure may be equippedwith suitable fastening elements which are configured in order to fastenthe reception structure, for example with a form and/or force fit, onsuitable counter-fastening elements of the housing structure of theapparatus. Corresponding fastening elements may be force-fit elements,i.e. for example bolt-like threaded elements, which allow force-fitfastening of the reception structure on suitable counter-fasteningelements, i.e. for example threaded bores, of the housing structure ofthe apparatus. Of course, a reversed configuration is likewise possible.

The reception structure may comprise separate reception compartments forreceiving functional elements associated with the coating device, i.e.for example respective application elements and respective, inparticular blade-like or blade-shaped, coating elements, and forreceiving functional elements associated with the illumination device,i.e. for example respective illumination elements, in particularconfigured as laser diode elements. There may also be separate receptioncompartments for respective application, coating and illuminationelements, which is useful for the aforementioned exact positioning andorientation of the coating device and of the illumination devicerelative to the construction plane.

Functional elements of further functional component parts of theapparatus may additionally be arranged or configured in the receptionstructure, i.e. in respective reception compartments provided therefor.Individual, several or all of the functional elements of furtherfunctional component parts of the apparatus may thus be arranged orconfigured in a structurally integrated way in the reception structure,in addition to the functional elements of the assembly. Correspondingarrangement or configuration of respective functional elements offurther functional component parts of the apparatus likewise requiresthat these further functional elements be arranged or configuredstatically on the housing structure of the apparatus.

A further functional component part of the apparatus, arranged orconfigured in a (further) reception compartment of the receptionstructure and therefore arranged or configured statically on the housingstructure of the apparatus, may for example be a suction device which isconfigured for suction of construction material detached from aconstruction material layer as a result of the construction process(“weld splashes”) and/or for suction of process gases produced as aresult of the construction process. The suction device comprises atleast one suction element, by means of which a suction flow can beformed which allows for removal of construction material detached from aconstruction material layer as a result of the construction processand/or for suction of process gases produced as a result of theconstruction process. It may be possible that a suction flow can flow orflows through the suction element, and that the latter iscorrespondingly coupled to a flow generating device, i.e. for example apump device. At least one passage opening for passage of an energy beamgenerated by the illumination device may be formed in the suctionelement. The suction element may have an elongate, in particulartube-like, optionally funnel-shaped, geometrical configuration.

A further functional component part of the apparatus, arranged orconfigured in a (further) reception compartment of the receptionstructure and therefore arranged or configured statically on the housingstructure of the apparatus, may (as an alternative or in addition) forexample be a smoothing and/or planarizing device which is configured forsmoothing and/or planarization, at least in sections, of a selectivelysolidified construction material layer. The smoothing and/or planarizingdevice comprises at least one smoothing and/or planarizing element, bymeans of which it can act on a selectively solidified constructionmaterial layer in order to remove nonuniformities produced as a resultof the construction process in the construction material layer, i.e. forexample crater-like elevations, in the construction material layer, i.e.smooth or planarize the construction material layer before a furtherconstruction material layer is formed thereon. The smoothing and/orplanarizing element may for example be configured as a scraper or asgrinding element which can optionally be driven in rotation (“grindingroller”).

A further functional component part of the apparatus, arranged orconfigured in a (further) reception compartment of the receptionstructure and therefore arranged or configured statically on the housingstructure of the apparatus, may (as an alternative or in addition) forexample be a detection device, which is configured in order to detect atleast one detection variable describing the quality of a constructionmaterial layer which is to be solidified and/or has been selectivelysolidified, i.e. in particular its surface. The detection devicecomprises at least one detection element, by means of which image dataof a construction material layer which is to be solidified and/or hasbeen selectively solidified can be recorded. The detection element mayfor example be configured as an optical imaging element, in particular acamera. Recorded image data can be evaluated qualitatively orquantitatively for particular detection variables describing the qualityof the construction material layer by means of suitable evaluationalgorithms. Corresponding detection variables may be features whichinfluence the quality of the construction material layer, i.e. forexample nonuniformities, for example crater-like elevations,irregularities, etc., of a construction material layer. The recorded,and optionally correspondingly evaluated, image data can be visualizedby means of suitable visualization algorithms, so that a two- orthree-dimensional (topological) image, in particular of the surface, ofa construction material layer can be compiled and displayed on asuitable display device, which optionally forms a constituent part ofthe apparatus.

Respective reception compartments of the reception structure may beconnectable or connected to one another releasably (without damage ordestruction) so as to form the reception structure, particularly in thehorizontal direction. The reception structure may therefore be assembledaccording to requirements from individual reception compartments whichcan be connected to one another, and can therefore for be made larger orsmaller according to requirements. To this end, suitable connectingelements are arranged or configured on respective receptioncompartments, by means of the interactions of which elements areleasable e.g. form-fit and/or force-fit connection of a plurality ofreception compartments on one another or to one another may be formed.Corresponding connecting elements may be form-fit elements, i.e. forexample latching projections, or force-fit elements, i.e. for examplebolt-like threaded elements, which allow form-fit or force-fit fasteningof a reception compartment on suitable form-fit counter-elements, i.e.for example latching recesses, or on suitable force-fitcounter-elements, i.e. for example threaded bores, of a furtherreception compartment.

The illumination device may comprise a plurality of illuminationelements, in particular combined in a plurality of groups, theseelements respectively being configured for generating an energy beam forselective illumination of a construction material layer to beselectively solidified. The coating device may be arranged or configuredbetween a first number of illumination elements, in particular a firstgroup of a plurality of illumination elements, and a second number ofillumination elements, in particular a second group of a plurality ofillumination elements. Such an arrangement of the coating device betweenrespective illumination elements of the illumination device is expedientfor the aforementioned conduct of simultaneous coating and illuminationprocesses during movement of the carrying element relative to theassembly. The arrangement may be structurally implemented in such a waythat a first number of illumination elements, in particular a firstgroup of illumination elements, is arranged or configured on a firstside region of the coating device, and a second number of illuminationelements, in particular a second group of illumination elements, isarranged or configured on a second side region of the coating device, inparticular lying opposite the first side region. Such an arrangement mayof course be produced using corresponding reception compartments, sothat a first number or group of illumination elements are arranged orconfigured in a first reception compartment, at least one applicationelement and at least one coating element are arranged or configured in asecond reception compartment arranged next to the first receptioncompartment, and a second number or group of illumination elements arearranged or configured in a third reception compartment next to thesecond reception compartment.

The coating device in this case comprises in principle at least oneapplication element and at least one coating element. In respect of thearrangement and number of respective application and coating elements,there are various configuration possibilities of the coating device:

According to a first exemplary configuration, the coating device maycomprise a plurality of coating elements arranged (directly) next to oneanother, and an optionally single application element. The applicationelement may be configured in order to apply a particular amount ofconstruction material between at least two coating elements onto theconstruction plane. The application element is therefore arrangedrelative to the coating elements in such a way that it can applyconstruction material into an intermediate space formed by at least twocoating elements arranged directly next to one another. The coatingelements may be mounted movably, for example in the vertical direction,between a coating position in which the formation of a defined ordesired construction material layer is possible, and a noncoatingposition in which the formation of a defined or desired constructionmaterial layer is not possible. Typically in every case a coatingelement is moved into the coating position and a coating element ismoved into the noncoating position in an alternating sequence.

According to a second exemplary configuration, the coating device maycomprise a plurality of application elements arranged next to oneanother and a (single) coating element. The application elements may beconfigured in order to apply a particular amount of constructionmaterial laterally next to the coating element, which is typicallyarranged or configured centrally between respective applicationelements, onto the construction plane. A first application element or agroup of first application elements may be arranged or configured to theleft of coating element, and a second application element or a group ofsecond application elements may be arranged or configured to the rightof the coating element.

For either configuration, it is the case that the application coatingelements—in a similar way to the illumination elements—typically can beor are arranged in a defined position and orientation, in particular ata defined distance, relative to the carrying element, in order to form adefined construction material layer.

In connection with the mentioned simultaneous conduct of coating andillumination processes, it is expedient for the carrying element to bemounted movably between a first position in which a first carryingelement section, in particular a carrying element section forming afirst end of the carrying element, is arranged below the coating device,and a second position in which a second carrying element section, inparticular a carrying element section forming a second end of thecarrying element, is arranged below the coating device.

On the basis of the first exemplary configuration of the coatingdevice—applicable for the case in which respective application andcoating elements associated with the coating device are arranged orconfigured between a first number of illumination elements, inparticular a first group of illumination elements, and a second numberof illumination elements, in particular a second group of illuminationelements—the formation of a construction material layer during movementof the carrying element starting from the first position in thedirection of the second position may be carried out by means of a firstcoating element. The application of construction material between thecoating elements is carried out by means of a correspondingly arrangedapplication element. In this case, the illumination of the constructionmaterial layer which has been formed, during the movement of thecarrying element in the direction of the second position, may be carriedout by means of at least one illumination element associated with thefirst number. In a similar way, the formation of a construction materiallayer during movement of the carrying element starting from the secondposition in the direction of the first position may be carried out bymeans of a second coating element. The application of constructionmaterial between the coating elements is again carried out by means of acorrespondingly arranged application element. The illumination of theconstruction material layer which has been formed may be carried outduring the movement of the carrying element in the direction of thefirst position by means of at least one illumination element associatedwith the second number.

On the basis of the second exemplary configuration of the coatingdevice—applicable for the case in which respective application andcoating elements associated with the coating device are arranged orconfigured between a first number of illumination elements, inparticular a first group of illumination elements, and a second numberof illumination elements, in particular a second group of illuminationelements—the application of construction material onto the constructionplane during movement of the carrying element starting from the firstposition in the direction of the second position may be carried out bymeans of a first application element. The formation of the constructionmaterial layer is carried out by means of a coating element arranged(centrally) between the application elements. Illumination of theconstruction material layer formed by means of the coating element maybe carried out during the movement of the carrying element in thedirection of the second position by means of at least one illuminationelement associated with the first number. The application ofconstruction material onto the construction plane may be carried outduring movement of the carrying element starting from the secondposition in the direction of the first position by means of a secondapplication element. The formation of the construction material layer isagain carried out by means of a coating element arranged (centrally)between the application elements. The illumination of the constructionmaterial layer formed by means of the coating element may be carried outduring the movement of the carrying element in the direction of thefirst position by means of at least one illumination element associatedwith the second number.

In respect of an exemplary plate-like or plate-shaped geometricalconfiguration of the carrying element, in the first position a left endregion of carrying element may be arranged below the coating device. Inthe second position, a right end region of the carrying element may bearranged below the coating device. The movement of a carrying elementlying in the first position therefore takes place to the left, in orderto move the carrying element into the second position. Correspondingly,the movement of a carrying element lying in the second positiontherefore takes place to the right, in order to move the carryingelement into the first position.

Overall, an application process, a coating process and an illuminationprocess may be carried out during each horizontal movement of thecarrying element relative to the assembly, i.e. independently of whetherit is being moved in the direction of the first or second position(“plotter principle”).

Individual, several or all of the illumination elements may be arrangedor configured on the reception structure in such a way that they can bemoved in at least one movement degree of freedom relative to theconstruction plane. By movable mounting of respective illuminationelements, it is possible to produce different illumination profiles, bymeans of which various solidification parameters, for examplesolidification degrees, of a construction material layer to besolidified may be varied. Temperature control of a construction materiallayer to be or which has been solidified, may also be envisioned bymeans of correspondingly configured illumination elements. Movements ofan illumination element may involve translational movement degrees offreedom along at least one translation axis and/or rotational movementdegrees of freedom about at least one rotation axis. Movement of anillumination element may therefore involve a linear movement along alinear movement axis (translation axis) and/or a revolving movementabout an axis of revolution (rotation axis). Of course, individual,several or all of the illumination elements may be movable incombination in different movement degrees of freedom. In a similar way,corresponding illumination elements may also be arranged or configuredon the reception structure so that they can be moved in at least onemovement degree of freedom relative to the construction plane. In thisway, the aforementioned movable mounting of a coating element betweenthe aforementioned coating position and the aforementioned noncoatingposition may be produced.

The apparatus may comprise a storage device, which is or can be assignedto the coating device, in particular respective application elements.The storage device is configured in order to store constructionmaterial. The storage device can be or is connected to the coatingdevice, in particular respective application elements, in such a waythat a particular amount of construction material can be delivereddiscontinuously or continuously by means of the storage device. Theamount of construction material delivered to the coating device isexpediently adapted to the movement of the carrying element, i.e. inparticular the speed of the carrying element, relative to the assembly.To this end, the storage device may be connected to a data memory devicein which particular movement profiles, in particular speed profiles, ofthe carrying element relative to the assembly are stored as data.

The carrying element, optionally the entire carrying device, expedientlyis vibrationally decoupled from the housing structure of the apparatus.This prevents the introduction of vibrations generated on duringmovements of the carrying element relative to the assembly, andconsequent possible impairment of illumination processes. Thevibrational decoupling is carried out by means of suitable decouplingelements or structures, i.e. for example elastomer elements orstructures, connected between the carrying element or the carryingdevice and the assembly.

The invention furthermore relates to a method for additive manufacturingof at least one three-dimensional object by successive layerwiseselective illumination and consequent solidification of individualconstruction material layers of solidifiable construction material bymeans of at least one energy beam. The method may be a selective lasermelting method (SLM method) or a selective laser sintering method (SLSmethod). The method is distinguished in that an apparatus as describedfor additive manufacturing of at least one three-dimensional object isused. All comments relating to the apparatus therefore apply similarlyfor the method.

The invention is explained in more detail with reference to exemplaryembodiments in the figures of the drawing, in which:

FIG. 1-22 each show a schematic representation of an apparatus foradditive manufacturing of a three-dimensional object according to oneexemplary embodiment.

FIG. 1 shows a schematic representation of an apparatus 1 according toone exemplary embodiment. The apparatus 1 serves for additivemanufacturing of a three-dimensional object, i.e. for example of atechnical component or a technical component group, by successivelayerwise selective illumination and consequent solidification ofconstruction material layers 9 of a solidifiable construction material 2by means of at least one energy beam 3. The successive layerwiseselective solidification of respective construction material layers 9 tobe solidified is carried out by one or more energy beams 3 beingdirected selectively onto particular regions corresponding to respectivelayer-related cross-sectional geometries of the object to be produced,of respective construction material layers 9 (“selective illumination”).

The solidifiable construction material 2 is for example a metal powder(mixture), i.e. for example an aluminum powder (mixture) or steel powder(mixture). The energy beam 3 is for example a laser, and the apparatus 1is therefore configured in order to carry out selective laser meltingmethods or selective laser sintering methods.

The apparatus 1 comprises a housing structure 4, in which the functionalcomponent parts of the apparatus 1, which are required in order to carryout additive construction processes, are arranged or configured. Thehousing structure 4 comprises an inertable process chamber 5. Aprotective gas atmosphere, i.e. for example an argon or nitrogenatmosphere, and/or a particular pressure level can be formed andmaintained in the process chamber 5.

The apparatus 1 comprises at least one combined coating and illuminationassembly 6, referred to below as an “assembly” for brevity. The assembly6 comprises a coating device 8 and an illumination device 11.

The coating device 8 is configured in order to carry out coatingprocesses in order to form construction material layers 9 to beselectively illuminated, or to be selectively solidified, in theconstruction plane 10, i.e. the plane in which corresponding coating andillumination processes are carried out. A construction material layer 9to be selectively illuminated and/or selectively solidified is formed ina respective coating process. The coating device 8 comprises one or moreapplication elements 27, 27 a, 27 b arranged or configured above theconstruction plane 10, optionally in a (parallel) arrangement andorientation next to one another, and comprising at least one applicationopening (not represented in detail), which can typically be closed bymeans of a closure element (not represented in detail) which can bemoved between an open position and a closed position, as well as one ormore blade-like or blade-shaped coating elements 12, optionally in a(parallel) arrangement and orientation next to one another.

A storage device 17 is assigned to the coating device 8, or therespective application elements 27, 27 a, 27 b. The storage device 17 isconfigured in order to store construction material 2. The storage device17 is connected to the coating device 8, or to the respectiveapplication elements 27, 27 a, 27 b, in such a way that a particularamount of construction material 2 can be delivered discontinuously orcontinuously by means of the storage device 17. The amount ofconstruction material 2 delivered to the coating device 8 may be adaptedto the movement (explained below) of the carrying element 16 of acarrying device 15, i.e. in particular the speed of the carrying element16, relative to the assembly 6.

The illumination device 11 is configured in order to carry outillumination processes for selective illumination and consequentselective solidification of construction material layers 9 formed in theconstruction plane 10 by means of the coating device 8. In a respectiveillumination process, a construction material layer 9 formed by means ofthe coating device 8 is selectively illuminated and thereforeselectively solidified. The illumination device 11 comprises a pluralityof illumination elements 13 arranged or configured above theconstruction plane 10. The illumination elements 13 are configured aslaser diode elements. It would also be conceivable for the illuminationelements 13 to be optical elements, particularly in lens form, coupledto laser diode elements (not shown), for example arranged outside thehousing structure 4, or to be scanner elements as part of an opticalscanner device.

The assembly 6 is arranged or configured statically, or fixed inposition, i.e. not movably, on the housing structure 4, i.e. typicallyon a wall associated with the housing structure 4 or on a fasteningdevice (not shown) arranged or configured on a wall associated with thehousing structure 4. The coating device 8, or the application elements27 and coating elements 12 associated therewith, as well as theillumination device 11, or the illumination elements 13 associatedtherewith, therefore lie in a defined position, i.e. in particular at adefined distance, and a defined orientation relative to the constructionplane 10. The static arrangement of the assembly 6 on the housingstructure 4 does not exclude the possibility that the assembly 6 maywhen required be separated from the housing structure, for example forservice and/or repair purposes. The assembly 6 may therefore be fastenedreleasably (without damage or destruction) on the housing structure 4.

The static arrangement, or configuration, of the assembly 6 on thehousing structure 4 is produced using a reception structure 14, which isfastened on the housing structure 4 and in which the coating device 8and the illumination device 11 are structurally integrated. Arrangementof the coating device 8 and of the illumination device 11 in thereception structure 14 gives rise to a structurally compactconfiguration of the assembly 6, as well as to exact positioning andorientation of the coating device 8, or of the application and coatingelements 12, 27, and of the illumination device 11, or of theillumination elements 13, relative to the construction plane 10. Inorder to fasten it on the housing structure 4, the reception structure14 is equipped with fastening elements (not represented in detail) whichare configured in order to fasten the reception structure 4, for examplewith a form and/or force fit, on suitable counter-fastening elements(not represented in detail) of the housing structure 4. Correspondingfastening elements may be force-fit elements, i.e. for example bolt-likethreaded elements, which allow force-fit fastening of the receptionstructure 4 on suitable counter-fastening elements, i.e. for examplethreaded bores, of the housing structure 4.

The reception structure 14 comprises separate reception compartments 14a, 14 b, 14 c for receiving the application and coating elements 12, 27associated with the coating device 8 and for receiving the illuminationelements 13 associated with the illumination device 11. Respectivereception compartments 14 a-14 c may be connected to one anotherreleasably (without damage or destruction) so as to form the receptionstructure 14, particularly in the horizontal direction. The receptionstructure 14 may therefore be assembled according to requirements fromindividual reception compartments 14 a-14 c, and can therefore be madelarger or smaller according to requirements. To this end, suitableconnecting elements (not represented in detail) are arranged orconfigured on the reception compartments 14 a-14 c, by means of theinteractions of which elements a releasable e.g. form-fit and/orforce-fit connection of a plurality of reception compartments 14 a-14 con one another or to one another may be formed. Corresponding connectingelements may be form-fit elements, i.e. for example latchingprojections, or force-fit elements, i.e. for example bolt-like threadedelements, which allow form-fit or force-fit fastening of a receptioncompartment 14 a-14 c on suitable form-fit counter-elements, i.e. forexample latching recesses, or on suitable force-fit counter-elements,i.e. for example threaded bores, of a further reception compartment 14a-14 c.

The arrangement of the application and coating elements 12, 27, and ofthe illumination elements 13, in respective reception compartments 14a-14 c is selected in such a way that the application and coatingelements 12, 27 are arranged between a first number of illuminationelements 13, i.e. a first group of a plurality of illumination elements13, and a second number of illumination elements 13, i.e. a second groupof a plurality of illumination elements 13. The arrangement isstructurally implemented in such a way that a first group ofillumination elements 13 is arranged in a first reception compartment 14a, the application and coating elements 12, 27 are arranged in at leastone second (further) reception compartment 14 b arranged next to thefirst reception compartment 14 a, and a second group of illuminationelements 13 is arranged in a third (further) reception compartment 14 cnext to the second reception compartment 14 b.

The apparatus 1 furthermore comprises a carrying device 15. A plate-likeor plate-shaped carrying element 16, which comprises the constructionplane 10, is associated with the carrying device 15. Before the start ofan additive construction process, the construction plane 10 is typicallyformed by the surface, or upper side, of the carrying element 16 facingtoward the assembly 6. The carrying element 16 is—as indicated by thehorizontally oriented double arrow—mounted movably in a horizontallyoriented movement plane, or movement path, relative to the assembly 6.Movements of the carrying element 16 in the horizontally orientedmovement plane, or movement path, are linear movements along a linearmovement axis (translation axis).

The carrying element 16 is—as indicated by the vertically orienteddouble arrow—also mounted movably in a vertical movement plane, ormovement path, relative to the assembly 6, besides the mobility in thehorizontal movement plane, or movement path. Respective movements of thecarrying element 16 in the vertically oriented movement plane, ormovement path, are typically linear movements along a linear movementaxis (translation axis), which are characteristic of correspondingadditive manufacturing methods after a coating and illumination processhas been carried out.

Movements of the carrying element 16 in the horizontal and/or verticalmovement plane, or movement path, are carried out by means of one ormore drive devices 18, which can be or are coupled to the carryingelement 16 and which will be discussed in more detail below.

The design configuration of the apparatus 1 allows movement of thecarrying element 16 relative to the assembly 6 in a horizontal movementplane, or movement path; with the aid of FIGS. 2 to 10 and FIGS. 11-20,it can be seen that the carrying element 16 can be moved to and fro in asimilar way to the principle of a plotter in the horizontal movementplane relative to the assembly 6. During respective movements of thecarrying element 16 relative to the assembly 6, both coating processesand illumination processes may be carried out. Movements of the carryingelement 16 relative to the assembly 6 therefore allow both theapplication of construction material 2, the formation of a definedconstruction material layer 9, and selective illumination of theconstruction material layer 9 which has been formed. The application,coating and illumination are thus respectively carried out during thehorizontal movement of the carrying element 16 relative to the assembly6. The apparatus 1 therefore allows simultaneous conduct of application,coating and illumination processes, so that down times or nonproductivetimes can be reduced, possibly even eliminated, and construction timescan correspondingly be optimized.

The simultaneous conduct of application, coating and illuminationprocesses will first be explained in more detail below with reference tothe schematic representations shown in FIGS. 2-10. Here, a firstexemplary configuration of the coating device 8 with a plurality ofcoating elements 12 a, 12 b arranged (directly) next to one another andan application element 27 is shown. The application element 27 isconfigured in order to apply a particular amount of constructionmaterial between the coating elements 12 a, 12 b onto the constructionplane 10.

The application element 27 is therefore arranged relative to the coatingelements 12 a, 12 b in such a way that it can apply constructionmaterial 2 into an intermediate space formed by the coating elements 12a, 12 b arranged directly next to one another. The coating elements 12a, 12 b may be mounted movably by means of suitable drive devices (notshown), for example in the vertical direction, between a coatingposition in which the formation of a defined or desired constructionmaterial layer 9 is possible, and a noncoating position in which theformation of a defined or desired construction material layer 9 is notpossible. Typically in every case a coating element 12 a, 12 b is movedinto the coating position and a coating element 12 a, 12 b is moved intothe noncoating position in an alternating sequence.

The carrying element 16 is mounted movably between a first position (cf.FIG. 2) in which a first carrying element section 16 a, i.e. for examplea carrying element section 16 a forming a first end region (right endregion) of the carrying element 16, is arranged below the coating device8, or the application element 27, and a second position (cf. FIG. 6) inwhich a second carrying element section 16 b, i.e. for example acarrying element section 16 b forming a second end region of thecarrying element 16, is arranged below the coating device 8, or theapplication element 27. In order to move the carrying element 16 lyingin the first position into the second position, a horizontal movement ofthe carrying element 16 to the right is carried out. Horizontal movementof the carrying element 16 in the direction of the second position isindicated by the arrow P1 shown in FIGS. 2-6. Conversely, a horizontalmovement of the carrying element 16 to the left is carried out in orderto move the carrying element 16 lying in the second position into thefirst position. Horizontal movement of the carrying element 16 in thedirection of the second position is indicated by the arrow P2 shown inFIGS. 6-10. In FIG. 10, the carrying element 16 is moved (back) into thefirst position. Of course, the first and second positions may beinterchanged; the comments above apply similarly.

On the basis of the configuration represented, in which the applicationelement 27 and the coating elements 12 a, 12 b are arranged between thefirst group of illumination elements 13 a (FIGS. 2-10, to the right ofthe coating device 8) and the second group of illumination elements 13 b(FIGS. 2-10, to the left of the coating device 8), the formation of aconstruction material layer 9 is carried out during movement (cf. arrowP1) of the carrying element 16 starting from the first position (cf.FIG. 2) in the direction of the second position (cf. FIG. 6) by means ofa first (right) coating element 12 a. The application of constructionmaterial 2 into the intermediate space formed between the coatingelements 12 a, 12 b is carried out by means of the application element27. In this context, FIGS. 2-6 are to be considered, with the aid ofwhich the horizontal movement of the carrying element 16 in thedirection of the arrow P1 starting from the first position, shown inFIG. 2, into the second position, shown in FIG. 6, can be seen. Theselective illumination of the construction material layer 9 which hasbeen formed, during the movement of the carrying element 16 in thedirection of the second position, is carried out by means of the (right)illumination elements 13 a associated with the first group. In a similarway, the formation of a further construction material layer 9 duringmovement of the carrying element 16 starting from the second position(cf. FIG. 6) in the direction of the first position (cf. FIGS. 2, 10) iscarried out by means of a second coating element 12 b. In this context,FIGS. 6-10 are to be considered, with the aid of which the horizontalmovement of the carrying element 16 in the direction of the arrow P2starting from the second position, shown in FIG. 6, (back) into thefirst position, shown in FIGS. 2, 10, can be seen. The selectiveillumination of the construction material layer 9 which has been formed,during the movement of the carrying element 16 in the direction of thefirst position, is carried out by means of the (left) illuminationelements 13 b associated with the second group.

The simultaneous conduct of application, coating and illuminationprocesses will also be explained in more detail below with reference tothe schematic representations shown in FIGS. 11-19. Here, a secondexemplary configuration of the coating device 8 with a plurality ofapplication elements 27 a, 27 b arranged next to one another and asingle coating element 12 arranged centrally between the applicationelements 27 a, 27 b is shown. A first application element 27 a isarranged to the left of the coating element 12, and a second applicationelement 27 b is arranged to the right of the coating element 12. Theapplication elements 27 a, 27 b are respectively configured in order toapply a particular amount of construction material laterally next to thecoating element 12, arranged centrally between the application elements27 a, 27 b, onto the construction plane 10.

The carrying element 16 is again mounted movably between a firstposition (cf. FIG. 11) in which a first carrying element section 16 a,i.e. for example a carrying element section 16 a forming a first endregion (right end region) of the carrying element 16, is arranged belowthe first application element 27 a, and a second position (cf. FIG. 15)in which a second carrying element section 16 b, i.e. for example acarrying element section 16 b forming a second end region of thecarrying element 16, is arranged below the second application element 27b. In order to move the carrying element 16 lying in the first positioninto the second position, a horizontal movement of the carrying element16 to the right is carried out (cf. FIGS. 11-14, arrow P1). Conversely,a horizontal movement of the carrying element 16 to the left is carriedout in order to move the carrying element 16 lying in the secondposition into the first position (cf. FIGS. 15-19, arrow P2). In FIG.19, the carrying element 16 is moved (back) into the first position. Ofcourse, the first and second positions may be interchanged; the commentsabove apply similarly.

Starting from the configuration represented, in which the applicationelements 27 a, 27 b and the coating element 12 are arranged between thefirst group of illumination elements 13 a (FIGS. 11-19, to the right ofthe coating device 8) and the second group of illumination elements 13 b(FIGS. 11-19, to the left of the coating device 8), the application ofconstruction material 2 during movement (cf. arrow P1) of the carryingelement 16 starting from the first position (cf. FIG. 2) in thedirection of the second position (cf. FIG. 6) is carried out by means ofthe first (left) application element 27 a. The formation of theconstruction material layer 9 is carried out by means of the centralcoating element 12. In this context, FIGS. 11-15 are to be considered,with the aid of which the horizontal movement of the carrying element 16in the direction of the arrow P1, starting from the first position asshown in FIG. 11 into the second position as shown in FIG. 15 can beseen. The selective illumination of the construction material layer 9which has been formed, during the movement of the carrying element 16 inthe direction of the second position, is carried out by means of the(right) illumination elements 13 a associated with the first group. In asimilar way, the application of further construction material 2, whichis required for the formation of a further construction material layer9, during movement of the carrying element 16 starting from the secondposition (cf. FIG. 15) in the direction of the first position (cf. FIGS.11, 19) is carried out by means of the second (right) applicationelement 27 b. The formation of the construction material layer 9 isagain carried out by means of the central coating element 12. In thiscontext, FIGS. 15-19 are to be considered, with the aid of which thehorizontal movement of the carrying element 16 in the direction of thearrow P2 starting from the second position as shown in FIG. 15 (back)into the first position as shown in FIGS. 11, 19 can be seen. Theselective illumination of the construction material layer 9 which hasbeen formed, during the movement of the carrying element 16 in thedirection of the first position, is carried out by means of the (left)illumination elements 13 b associated with the second group.

What is essential for the additive manufacturing process, in all cases,is that, before it is moved back into the first position, the carryingelement 16 moved into the second position is moved, i.e. lowered, by aparticular amount in the vertical direction, as indicated in FIGS. 6,15. This vertical movement (lowering) of the carrying element 16 allowsthe formation, on a previously selectively solidified constructionmaterial layer 9, of a further construction material layer 9 to beselectively solidified and the selective illumination of thisconstruction material layer 9 during the movement of the carryingelement 16 back into the first position. In a similar way, the carryingelement 16 moved back into the first position is moved, i.e. lowered, bya particular amount in the vertical direction. This vertical movement ofthe carrying element 16 allows the formation, on the previouslyselectively solidified construction material layer 9, of a furtherconstruction material layer 9 to be selectively solidified and theselective illumination of this construction material layer 9 during themovement of the carrying element 16 back into the second position.

Overall, an application process, a coating process and an illuminationprocess may be carried out during each horizontal movement of thecarrying element 16 relative to the assembly 6, i.e. independently ofwhether it is being moved in the direction of the first or secondposition (“plotter principle”).

FIGS. 20, 21 respectively show a schematic representation of anapparatus 1 according to a further exemplary embodiment. Differentvariants for the conduct of respective movements of the carrying element16 in the horizontally oriented movement plane relative to the assembly6 can be seen with the aid of the exemplary embodiment shown in FIGS.20, 21.

In the first variant, shown in FIG. 20, the carrying element 16 isarranged in a modular housing structure 19 (“construction container”),which is mounted movably in a horizontal direction, of the carryingdevice 15. The modular housing structure 19 is mounted movably in thehorizontally oriented movement plane relative to the static assembly 6.It is thus not the carrying element 16 itself, but the entire modularhousing structure 19, in which the carrying element 16 is arranged, thatis mounted movably in the horizontal direction relative to the assembly6. Movements of the carrying element 16 relative to the assembly 6therefore result from movements of the modular housing structure 19relative to the assembly 6. The carrying element 16 is arrangedstatically in the horizontal direction in the modular housing structure19.

For driving, i.e. for setting the modular housing structure 19 inmovement in the horizontally oriented movement plane relative to theassembly 6, the apparatus 1 comprises a drive device 18. The drivedevice 18 is coupled to the modular housing structure 19, and isconfigured in order to generate a drive force which moves the modularhousing structure 19 in the horizontally oriented movement planerelative to the assembly. The drive device 18 may be configured as alinear drive. Specifically, the drive device 18 may be configured, forexample, as a crank drive or a spindle drive. In order to carry out aguided movement of the modular housing structure 19 in the horizontalmovement plane, or movement path, an e.g. rail-like guide device 20 maybe arranged or configured in the housing structure 4 of the apparatus.

In the variant shown in FIG. 21, the carrying element 16 is arranged ina modular housing structure 19 of the carrying device 15, which isarranged or configured statically relative to the assembly 6. In thiscase, the carrying element 16 is thus mounted movably in(side) themodular housing structure 19 in the horizontally oriented movementdirection relative to the assembly 6. The carrying element 16 is thusitself mounted movably in the horizontal direction relative to theassembly 6. Movements of the carrying element 16 relative to theassembly 6 therefore result from actual movements of the carryingelement 16 inside and relative to the modular housing structure 19. Themodular housing structure 19 is arranged statically in the horizontaldirection on or in the housing structure 4 of the apparatus.

For driving, i.e. for setting the carrying element 16 in movement in thehorizontally oriented movement plane relative to the assembly 6, themodular housing structure 19 comprises a drive device 18. The drivedevice 18 is coupled to the carrying element 16, and is configured inorder to generate a drive force which moves the carrying device 16 inthe horizontally oriented movement plane relative to the assembly 6. Thedrive device 18 may in this case also be configured as a linear drive.The drive device 18 may therefore in this case also be configured, forexample, as a crank drive or a spindle drive. In order to carry out aguided movement of the carrying element 16 in the horizontal movementplane, or movement path, an e.g. rail-like guide device 20 may bearranged or configured in the modular housing structure 19. The guidedevice 20 may be mounted movably in the vertical direction, in order tocarry out lowering of the carrying element 16.

For the variants shown in FIGS. 20, 21, it is likewise the case that themodular housing structure 19 can be removed in the manner of areplaceable container from the housing structure 4 of the apparatus. Themodular housing structure 19, or the carrying device 15, can thereforebe removed when required from the housing structure 4 of the apparatus,and fastened when required on the housing structure 4 of the apparatus.

FIG. 22 shows a schematic representation of an apparatus 1 according toanother exemplary embodiment. With the aid of the exemplary embodimentshown in FIG. 22, it can be seen that functional elements of furtherfunctional component parts of the apparatus 1 may additionally bearranged or configured in the reception structure 14, i.e. in respectivereception compartments 14 a-14 i provided therefor, and may therefore bearranged or configured in a structurally integrated way in the receptionstructure 14. Corresponding arrangement or configuration of respectivefunctional elements of further functional component parts of theapparatus 1 likewise requires that these further functional elements toobe arranged or configured statically, or fixed in position, on thehousing structure 4 of the apparatus.

Corresponding further functional component parts of the apparatus 1 are,in the exemplary embodiment shown in FIG. 22, a suction device 21, asmoothing and/or planarizing device 22, and a detection device 23. Itcan be seen that the aforementioned functional component parts of theapparatus 1, or the functional elements associated with them, arepresent in a symmetrical and therefore redundant arrangement withrespect to the centrally arranged coating device 8.

The suction device 21 is used for suction of construction material 2detached from a construction material layer 9 as a result of theconstruction process (“weld splashes”) and/or for suction of processgases produced as a result of the construction process. The suctiondevice 21 comprises suction elements 24, by means of which it ispossible to form a suction flow that allows for removal of constructionmaterial detached from a construction material layer 9 as a result ofthe construction process and/or for suction of process gases produced asa result of the construction process. The suction elements 24 arearranged in the reception compartments 14 d, 14 g arranged next to thereception compartments 14 a, 14 c which receive the illuminationelements 13.

The smoothing and/or planarizing device 22 is configured for smoothingand/or planarization of selectively solidified construction materiallayers 9. The smoothing and/or planarizing device 22 comprises smoothingand/or planarizing elements 25, by means of which it can actmechanically on a selectively solidified construction material layer 9in order to remove nonuniformities produced as a result of theconstruction process in the construction material layer 9, i.e. forexample crater-like elevations, i.e. smooth or planarize theconstruction material layer 9 before a further construction materiallayer 9 is formed thereon. The smoothing and/or planarizing elements 25are configured for example as grinding elements which can be driven inrotation (‘grinding rollers’) The smoothing and/or planarizing elements25 are arranged in the reception compartments 14 e, 14 h arranged nextto the reception compartments 14 d, 14 g which receive the suctionelements 24.

The detection device 23 is configured in order to detect at least onedetection variable describing the quality of a construction materiallayer 9 which is to be solidified and/or has been selectivelysolidified, i.e. in particular its surface. The detection device 23comprises detection elements 26, by means of which image data of aconstruction material layer 9 which is to be solidified and/or has beenselectively solidified can be recorded. The detection elements 26 areconfigured as optical imaging elements, in particular as cameras. Thedetection elements 26 are arranged in the reception compartments 14 f,14 i arranged next to the reception compartments 14 e, 14 h whichreceive the smoothing and/or planarizing elements 25.

Image data recorded by means of the detection elements 26 are evaluatedqualitatively or quantitatively for particular detection variablesdescribing the quality of the construction material layer 9 by means ofsuitable evaluation algorithms. Corresponding detection variables may befeatures which influence the quality of the construction material layer9, i.e. for example nonuniformities, for example crater-like elevations,irregularities, etc., of a construction material layer 9. The recorded,and optionally correspondingly evaluated, image data may be visualizedby means of suitable visualization algorithms, so that a two- orthree-dimensional (topological) image, in particular of the surface, ofa construction material layer 9 can be compiled and displayed on asuitable display device (not shown), which optionally forms aconstituent part of the apparatus 1.

For all the exemplary embodiments shown in the Figs, it is the case thatthe carrying element 16, optionally the entire carrying device 15 may bevibrationally decoupled from the housing structure 4 of the apparatus.This prevents the introduction of vibrations generated during movementsof the carrying element 16 relative to the assembly 6, and consequentpossible impairment of illumination processes. The vibrationaldecoupling is carried out by means of suitable decoupling elements (notrepresented in detail) or structures, i.e. for example elastomerelements or structures, connected between the carrying element 16 or thecarrying device 15 and the assembly 6.

By means of the apparatuses 1 shown in the Figs, a method for additivemanufacturing of a three-dimensional object by successive layerwiseselective solidification of construction material layers of solidifiableconstruction material 2 by means of at least one energy beam 3 mayrespectively be carried out. The method may be a selective laser meltingmethod (SLM method) or a selective laser sintering method (SLS method).

Individual, several or all of the features presented in relation to aparticular exemplary embodiment may be applied to at least one otherexemplary embodiment.

LIST OF REFERENCES

-   1 apparatus-   2 construction material-   3 energy beam-   4 housing structure-   5 process chamber-   6 assembly-   8 coating device-   9 construction material layer-   10 construction plane-   11 illumination device-   12 coating element-   13 illumination element-   14 reception structure-   14 a-i reception compartment-   15 carrying device-   16 carrying element-   17 storage device-   18 drive device-   19 modular housing structure-   20 guide device-   21 suction device-   22 smoothing and/or planarizing device-   23 detection device-   24 suction element-   25 smoothing and/or planarizing element-   26 detection element-   27 application element-   P1-P3 arrow

The invention claimed is:
 1. An apparatus for additive manufacturing ofa three-dimensional object by successive layer-by-layer selectiveillumination and selective solidification of construction materiallayers formed in a construction plane having a construction materialthat can be solidified by at least one energy beam, the apparatuscomprising: a housing structure; a combined coating and illuminationassembly arranged or formed on the housing structure of the apparatus,comprising: a coating device provided for applying the constructionmaterial into the construction plane and for forming constructionmaterial layers to be solidified in the construction plane, the coatingdevice comprising: a first application element; a second applicationelement arranged adjacently to the first application element; and acoating element disposed between the first application element and thesecond application element; and an illumination device provided for theselective illumination of respective construction material layers formedin the construction plane by the coating device; and a carrying devicewhich comprises at least one carrying element that comprises theconstruction plane and is movably supported in a horizontal movementplane relative to the combined coating and illumination assembly;wherein each of the first and second application elements is provided toapply a certain amount of construction material onto the constructionplane laterally adjacent to the coating element, wherein the applicationof a construction material onto the construction plane is performed:with the first application element when moving the carrying element froma first position towards a second position, and with the secondapplication element when moving the carrying element from the secondposition towards the first position.
 2. The apparatus as claimed inclaim 1, wherein the carrying element is formed on or in a movablysupported modular housing structure of the carrying device, wherein themodular housing structure is movably supported in the horizontalmovement plane relative to the combined coating and illuminationassembly.
 3. The apparatus as claimed in claim 2, further comprising atleast one drive unit that can be coupled with or is coupled with themodular housing structure of the carrying device or the carryingelement, the at least one drive unit provided to create a driving forcemoving the modular housing structure or the carrying element in thehorizontal movement plane relative to the combined coating andillumination assembly.
 4. The apparatus as claimed in claim 1, furthercomprising at least one of: a suction device arranged or formed on thehousing structure of the apparatus, the suction device provided for thesuction of construction material loosened from a construction materiallayer related to the construction process and/or for the suction ofprocess gases arising related to the construction process; a smoothingand/or planarizing device firmly arranged or formed on the housingstructure of the apparatus, which is provided for at least partiallysmoothing and/or planarizing a selectively solidified constructionmaterial layer; or a detection device arranged or formed on the housingstructure of the apparatus, which is provided for the detection of atleast one detection variable describing the quality of a constructionmaterial layer that is to be solidified and/or is selectivelysolidified.
 5. The apparatus as claimed in claim 1, further comprising:a reception structure attached to the housing structure of theapparatus, in which at least the coating device and the illuminationdevice arranged or formed in a structurally integrated manner.
 6. Theapparatus as claimed in claim 5, wherein the reception structurecomprises a plurality of separate reception compartments, whereinrespective functional elements associated with the coating device, andrespective functional elements associated with the illumination deviceare arranged in said separate reception compartments respectivelyassociated.
 7. The apparatus as claimed in claim 6, wherein respectivereception compartments are removably connected with each other duringforming the reception structure.
 8. The apparatus as claimed in claim 1,wherein the illumination device comprises a plurality of illuminationelements respectively provided for the generation of an energy beam forthe selective illumination of a construction material layer to beselectively solidified, wherein the coating device is arranged or formedbetween a first number of illumination elements, and a second number ofillumination elements.
 9. The apparatus as claimed in claim 1, whereinthe coating device comprises a plurality of coating elements adjacentlyarranged, and at least one further application element, wherein the atleast one further application element is provided to apply a certainamount of construction material between at least two of the plurality ofcoating elements onto the construction plane.
 10. The apparatus asclaimed in claim 1, wherein the carrying element is movable between: thefirst position in which a first carrying element portion is movablyarranged below the coating device, and the second position in which asecond carrying element portion is movably arranged below the coatingdevice.
 11. The apparatus as claimed in claim 8, wherein the coatingdevice comprises: a plurality of coating elements adjacently arranged,and at least one further application element, wherein the at least onefurther application element is provided to apply a certain amount ofconstruction material onto the construction plane between at least twoof the plurality of coating elements, wherein forming of a constructionmaterial layer is performed when moving the carrying element from thefirst position towards the second position via a first coating element,and the illumination of the formed construction material layer isperformed during the movement of the carrying element towards the secondposition by at least one of the illumination elements associated withthe first number, and forming of a construction material layer isperformed when moving the carrying element from the second positiontowards the first position via a second coating element, and theillumination of the formed construction material layer is performedduring the movement of the carrying element towards the first positionby at least one of the illumination elements associated with the secondnumber.
 12. The apparatus as claimed in claim 8, wherein theillumination of the construction material layer formed by the coatingelement is performed during the movement of the carrying element towardsthe second position by at least one of the illumination elementsassociated with the first number, and the illumination of theconstruction material layer formed by the coating element is performedduring the movement of the carrying element towards the first positionby at least one of the illumination elements associated with the secondnumber.
 13. The apparatus as claimed in claim 10, wherein the carryingelement is supported vertically movably.
 14. The apparatus as claimed inclaim 1, wherein at least the carrying element of the housing structureof the device is vibration-isolated.
 15. The apparatus as claimed inclaim 1, further comprising a supply device associated with the coatingdevice, wherein the supply device can be connected with or is connectedwith the coating device such that a certain amount of constructionmaterial can be continuously or discontinuously supplied to the coatingdevice via the supply device.
 16. The apparatus as claimed in claim 1,wherein an illumination element is formed as a laser diode element or anoptical element that can be coupled with or is coupled with a laserdiode element, or as a scanner element as part of an optical scannerdevice.
 17. A method for additive manufacturing of at least onethree-dimensional object by successive, selective layer-by-layerillumination and thus solidification of individual construction materiallayers of a construction material that can be solidified with an energybeam, the method comprising: selectively illuminating, with anillumination device of a combined coating and illumination assembly,respective construction material layers formed in a construction planeby a coating device; movably supporting a carrying device, comprising atleast one carrying element that comprises the construction plane,relative to the combined coating and illumination assembly in ahorizontal movement plane; applying, with a first application element ofthe coating device, a certain amount of construction material onto theconstruction plane when moving the carrying element from a firstposition towards a second position; applying, with a second applicationelement of the coating device adjacently arranged to the firstapplication element, a certain amount of construction material onto theconstruction plane when moving the carrying element from the secondposition towards the first position; and coating, with a coating elementof the coating device disposed between the first and second applicationelements, a construction material to the construction plane for formingconstruction material layers.
 18. The apparatus according to claim 1,wherein the carrying element is arranged or formed on or in a modularhousing structure of the carrying device that is arranged or formedrelative to the combined coating or illumination assembly, wherein thecarrying element is movably supported on or in the modular housingstructure in the horizontal movement plane relative to the combinedcoating and illumination assembly.
 19. The apparatus as claimed in claim14, wherein the entire carrying device of the housing structure of thedevice is vibration-isolated.
 20. The method as claimed in claim 17,wherein the at least one carrying element is formed on or in a movablysupported modular housing structure of the carrying device, wherein themodular housing structure is movably supported in the horizontalmovement plane relative to the combined coating and illuminationassembly.